Structural building panels with interlocking seams

ABSTRACT

Systems and methods providing a modular building having pre-fabricated panel wall components are easily assembled to form a predetermined, energy efficient structure that provides for mating alignment and securement of the modular panels with each other along their adjoining seams.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.12/493,375, filed Jun. 29, 2009, and U.S. application Ser. No.12/493,394, filed Jun. 29, 2009, both of which are herein incorporatedby reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to modular building systems andmethods, and more particularly, to modular building systems and methodsfor making them and for installing them to form a building structure.

2. Description of the Prior Art

Modular buildings and components used in making them are known in theart. By way of example, prefabricated housing components, including wallpanels are known. However, after windows and doors, energy losses mostcommonly occur in the seam or joint regions of structures, includingprefabricated buildings and modular structural components. Additionally,while prefabricated panels and other components are known in the art,they are not structured or configured for quick and easy assembly toform a predetermined completed structure that also provides for anenergy efficient structure that is also stable and reliable, i.e., ableto withstand the natural elements including storm conditions. Sheerforces produced by large wind events (i.e. hurricanes, etc.) or seismic(earthquake) events can quickly render traditional building cornersineffective at maintaining the structural integrity of the building.There further exists a need for energy efficient structures that preventheat and/or cooling losses through the seam or joint region of thestructure, which, after windows and doors, is the most common area ofenergy loss in modular building structures.

Examples of relevant art includes the following U.S. patent documents:

U.S. Pat. No. 6,564,521, issued May 20, 2003 to Brown et al. for“Structural sandwich panels and method of manufacture of structuralsandwich panels,” teaches rigid structural members, profiles, joints,and forms added to structural sandwich panels to provide higherstrength, integral joining joint and single facing sheet manufacturing.The joints provide for mating alignment via vertically oriented rigidmembers and corresponding elongated recesses. However, these members areprovided for alignment and require the securement of joined abuttingstructural sandwich panels together with cam-locks.

U.S. Pat. No. 5,344,700 for “Structural panels and joint connectorarrangement therefore,” describes a tongue-in-groove joint combined witha rod-like connecting mechanism.

U.S. Pat. No. 5,373,678 for “Structural panel system” also usestongue-in-groove joints.

U.S. Pat. No. 5,950,389 for “Splines for joining panels” and U.S. Pat.No. 5,628,158 for “Structural insulated panels joined by insulated metalfaced splines,” which provides for metal splines that are glued intoslots in adjacent panels.

U.S. Pat. No. 5,842,314 for “Metal reinforcement of gypsum, concrete orcement structural insulated panels” and U.S. Pat. No. 5,349,796 for“Building panel & method” teach improvements for reinforcement andstrengthening structural panels using metal strips, and shear railstructures that function like I-beams to strengthen the panel,respectively.

U.S. Pat. No. 5,519,971 for “Building panel, manufacturing method andpanel assembly system,” and U.S. Pat. No. 5,373,678 for “Structuralpanel system” describe the use of a header to interconnect adjacentpanels; notably, the header is not mentioned in connection with anincreased load-bearing capacity for the panels.

None of the prior art addresses the longstanding need for stable, energyefficient modular building structures, including kits for installingsame, in particular having structurally locked wall panel componentsthat are aligned with a mating multiple rail track and interlocking orinterconnecting edge system. Thus there remains a need for energyefficient and stable modular building systems and methods formanufacturing and for installing them to form a building structurehaving energy efficient seams that provide for simultaneous alignmentand friction-based locking of the panels at the joints.

SUMMARY OF THE INVENTION

The present invention provides modular building systems and methods formanufacturing and installing them.

One aspect of the present invention is to provide systems for a modularbuilding having structural prefabricated wall panel components that arejuxtapositioned, aligned and interconnected along their edges to formjoints or seams, wherein the wall components are assembled and locked inplace to form an energy efficient and stable modular buildings includingenergy efficient seams that provide for simultaneous alignment andfriction-based locking of the panels at the joints, and furtherincluding energy efficient modular components that provide for seamless,insulated corners and panels.

Another aspect of the present invention is to provide methods formanufacturing energy efficient and stable modular building systemshaving energy efficient seams or joints including energy efficientcorners and panels that are seamless and that provide for simultaneousalignment and friction-based locking of the panels at the joints.

Another aspect of the present invention is to provide methods forinstalling energy efficient and stable modular building systems havingenergy efficient seams or joints including energy efficient corners andpanels that are seamless and that provide for simultaneous alignment andfriction-based locking of the panels at the joints.

Another aspect of the present invention is to provide a modular panelthat is either insulative or non-insulative, but that still providesenergy efficient corners that are seamless and that provide forstructural integrity and strength.

Still another aspect of the present invention is to provide a modularbuilding system with prefabricated composite wall panels that includeconduits in the panel body with conduit input/output openings alongpredetermined edge areas of the panel body, and energy efficient seamsor joints that provide for simultaneous alignment and friction-basedlocking of the panels at the joints. Methods for manufacturing andinstallation of the modular building systems are also considered aspectsof the present invention. These and other aspects of the presentinvention will become apparent to those skilled in the art after areading of the following description of the preferred embodiment whenconsidered with the drawings, as they support the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-31 illustrate various views related to the present invention.

FIG. 1 illustrates a perspective view of a partially assembled modularbuilding structure.

FIG. 2 shows a perspective view of a completed modular building from thepartially completed illustration of FIG. 1.

FIG. 3 illustrates several related views; in FIG. 3A a top view of twoedges of modular wall panels having mating double railing for alignmentand locking mechanism; FIG. 3B illustrates an end perspective viewillustrating the parallel spaced apart double track or railing system;FIG. 3C illustrates a side view and cut-away of joined panel edges withthe interlocking cam-based locking mechanism.

FIG. 4 illustrates a top view of a corner wall panel modular componentwith seamless corner and two wall component segments integrallyconnected therewith and extending outwardly therefrom.

FIG. 5A illustrates a top view of a corner wall panel modular componentwith seamless corner and two wall component segments extending outwardlytherefrom.

FIG. 5B illustrates a “T” cross-section a top view of a corner wallpanel modular component with seamless corner and three wall componentsegments extending outwardly therefrom.

FIG. 5C illustrates a “+” cross-section a top view of a corner wallpanel modular component with seamless corner and four wall componentsegments extending outwardly therefrom.

FIG. 6 illustrates several perspective views of the modular buildingcomponents including FIG. 6A showing a basic flat wall panel component;FIG. 6B showing a 90 degree corner panel component; FIG. 6C showing a135 degree angle corner panel or transition panel; FIG. 6D showing awindow opening in a wall panel component; FIG. 6E showing a door openingin a wall panel component.

FIG. 7 illustrates an exploded view of various component panels.

FIG. 8 illustrates various component roof panels.

FIG. 9 illustrates a cut-away partial side view of a wall panelinstallation according to one aspect of the present invention.

FIG. 10A illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention; FIG. 10Billustrates a partial perspective view of a section of FIG. 10A; FIG.10C shows a cut-away side view of a section of FIG. 10A.

FIG. 11 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention.

FIG. 12 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention, includingtwo stages of corner panel installation. FIG. 12A illustrates theinstallation of the one piece corner first and FIG. 12B illustratessubsequent installation of a wall panel over the plate.

FIG. 13 illustrates a cut-away partial perspective view of a wall panelinstallation of two components constructed and configured for connectionfollowing the step illustrated in FIG. 12B.

FIG. 14 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention, includinga unitary and integral single component seamless corner panel and wallpanel components connected thereto.

FIG. 15A and FIG. 15B illustrate a cut-away partial perspective view ofa wall panel installation according to one aspect of the presentinvention with a window panel and door panel, respectively.

FIG. 16A illustrates a cut-away partial perspective view of a wall panelfor a non-load bearing split window panel; FIG. 16B illustrates astandard wall panel with window section (non-split); FIG. 16Cillustrates a cut-away partial perspective view of a wall panel for aload bearing split window panel; FIG. 16D illustrates a front view ofFIG. 16C components when assembled.

FIG. 17 illustrates a partial perspective view of wall panel componentswhen assembled at a seam.

FIG. 18A illustrates a perspective view of an adjuster panel withasymmetrically mating seams (male and female mating seams); FIG. 18Billustrates a perspective view of an adjuster panel with symmetricalmating seams (female-female with double strip spline connector) andconnector.

FIG. 19 illustrates components and steps for reassembly.

FIG. 20 illustrates a cut-away partial front view of an assemblyincluding components of the present invention.

FIG. 21 illustrates a cut-away partial front view of a ridge panel forroof installation.

FIG. 22 illustrates a cut-away partial perspective view of a roofinstallation including panels.

FIG. 23 illustrates components and steps for assembly of split panelshaving beam pockets as shown assembled in FIG. 17.

FIG. 24 illustrates another embodiment of components and steps forassembly of split panels having beam pockets.

FIG. 25A illustrates a cut-away partial perspective view of a headercondition component wall panel; FIG. 25B illustrates a cut-away partialperspective view of a co-linear condition component wall panel.

FIG. 26 illustrates a partial cut-away front view of an installation ofcomponents according to the present invention.

FIGS. 27A and 27B illustrate partial perspective views of wall panelswith overhanging roof detail and flush roof detail, respectively.

FIG. 28 illustrates a front partial view of an overhand roof assembly.

FIG. 29 illustrates a partial perspective view of a roof assembly,including a close-up view of a female camlock area of a roof panelaccording to the present invention.

FIG. 30 illustrates a cross-sectional view of a panel.

FIG. 31 illustrates the x-, y- and z-dimensions of a panel.

DETAILED DESCRIPTION

In the following description, like reference characters designate likeor corresponding parts throughout the several views. Also in thefollowing description, it is to be understood that such terms as“forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,”“downwardly,” and the like are words of convenience and are not to beconstrued as limiting terms.

The present invention provides systems and methods for an energyefficient and stable modular building that is self-contained within astandard shipping container, wherein systems and methods formanufacturing and for installing them to form a building structurehaving energy efficient seams that provide for simultaneous alignmentand friction-based locking of the panels at the joints. Moreparticularly these systems and methods include pre-fabricated andinsulated panel wall components that are easily assembled viainterlocking or interconnecting edges that provide for at least somefriction-based locking when connected to form a predetermined structure.These systems and methods may further include energy efficient cornermodulars that provider for seamless, insulated corners. Further,additional locking mechanisms for increased securement and locking of atleast two wall panel components at their joined edges or seams areprovided, for example using a cam-based component connector system.

In one embodiment, a cam-based connector provides for mating alignmentand locking of the modular panel components with each other along theiradjoining seams wherein the cam based connector extends between a firstunlocked position and a second position. At least two edges are firstaligned by the mating, dual track alignment seams when the cam-basedconnector is in the first position and then the connector is moved tothe second position to lock the wall components together. While theinterlocking cam mechanism is desirable for providing additionalsecurement at the joints between two panels, it is not a requirement forstability. The cam based connector has a female and a male component—themale component having a base and an arm or hook, the base allowing for atool or key to be inserted and rotated in order to rotate the arm orhook. The female component receives the arm or hook, optionally throughthe use of a pin over which a hook may rest and lock.

Another aspect of the present invention is to provide a modular buildingsystem with prefabricated composite wall panels having the interlockingor interconnecting edges having friction-based seams that furtherinclude conduits provided within the panels; these conduits mayoptionally be pre-wired. Methods for installation of the modularbuilding system include the steps of providing prefabricated modularbuilding components, including modular panel components having edgeswith interconnecting interfaces for aligning, connecting, and securingpanel components together at their edges and forming an energy efficientseam thereby, and further including energy efficient corner modularcomponents that provide for seamless, insulated corners; assembling themodular housing by arranging and connecting the composite wall panels,which may include conduits for electrical and/or plumbing disposedwithin the interior section of the composite wall panels, includinginput/output openings for wiring, etc. Further, the methods may includeprefabricated modular wall panels and instructions for assembly;arranging, aligning, and connecting the composite wall panels at theirmating edges for providing friction-based locking of at least twopanels. Also, steps for activating additional locking or securementmechanisms for two joined panels at the seam areas are provided.

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto. As illustrated in thefigures, components of a modular building are shown, including modularwall panel components having edges for matingly interlocking orinterconnecting at least two panels at those edges to from a seam.Modular building materials are shown including interlockingpre-engineered and pre-insulated panels that are constructed andconfigured to be quickly attached together by juxtapositioning,aligning, interconnecting, and securedly connecting two panel componentsof the interleavable laminae along their respective edges to form thewalls, roof, and/or floor of a structure. The figures further includeconnecting energy efficient corner modular components that provide forseamless, insulated corners, wherein the corner modular components areconnected to other non-corner modular components, i.e., wall panelcomponents, at corresponding edges as for described herein for aligning,connecting or joining, and securing the basic wall panel components.

The present invention provides for systems and methods for a modularbuilding having structural prefabricated wall panel components that arejuxtapositioned, aligned and interconnected along their edges to formjoints or seams, wherein the wall components are aligned, assembled,connected and locked in place along corresponding or mating edgesthereby forming seams, and by connecting a multiplicity of predeterminedpanel component overall to form an energy efficient and stable modularbuildings including energy efficient seams that provide for simultaneousalignment and friction-based locking of the panels at the joints;wherein the alignment and interconnection of the panels is provided inone embodiment by at least two mating vertically oriented rail systemsthat are connected to and protrude from and extend along the length ofan edge of the wall panel body and wherein two wall panels areconnectable by aligning the mating edges of the two panels and theninterconnecting the rail systems, thereby providing the alignment andsecurement of the panels at those edges or seams formed at the joinededges of two panels.

In one embodiment, the at least two vertically oriented rails systemsinclude spaced apart rails that matingly correspond to receptivecavities in the mating panel edge, so that when the two panels arealigned, connected and joined at these edges, the rail system providesfor mating securement of the panels. Preferably, the corresponding edgesinclude one edge with protruding rails and the opposite edge havingcavities sized, shaped and configured for receiving the protruding railsystem counterparts. In another embodiment, the rails on one edge arealternatingly spaced apart with the protruding rail having a matingreceiving cavity disposed therebetween. In another embodiment, the railsare spaced apart with no cavity disposed therebetween, such that theseam is formed not by abutting wall panel bodies wherein the seam orjoint exists at the direct connection of the panel edges, but that theseam is formed by interleaved protruding rails that form an aligned,friction-based locking of the joined wall panel bodies. In this way, therails form interleaved laminae whose surface area of overlapping laminaecreate a seam, thus eliminating the need for sealing gaskets. The seamthickness may be equivalent to the wall panel body thickness, or it maybe less than the thickness of the wall panel body; if the latter, thenadditional insulation, covering material, or tape is provided to ensureseam thickness consistency with the wall panel body.

In one embodiment, the overlapping laminae are substantially parallel,which allows for greater friction to be created due to the increasedoverlapping surface area as compared to laminae that are configured tobe angled towards each other.

In one embodiment, the rail system is continuous. Alternatively, insteadof or combined with at least one continuous protruding rail on an edge,the system includes discrete protruding tabs that are spaced apart alongthe length of the edge, and wherein corresponding cavities for receivingthose protruding tabs are provided.

Preferably, the modular building system with prefabricated compositewall panels of the present invention may be constructed and configuredto include conduits in the panel body with conduit input/output openingsalong predetermined edge areas of the panel body, and energy efficientseams or joints that provide for simultaneous alignment andfriction-based locking of the panels at the joints.

Thus the present invention provides for energy efficient and stablemodular building systems having energy efficient seams or joints thatprovide for simultaneous alignment and friction-based locking of thepanels at the joints, without requiring any additional securementmechanism at the joints for ensuring stability of the connected panelsat those joints or seams.

Preferably, the corner panel component is constructed and configured toform at least one “L-shaped” corner; however, multiple corners may beprovided by a single corner panel component, including by way of exampleand not limitation, a “T” cross-section or a “+” cross-section, whenviewed from the top. In preferred embodiments, the corner element isestablished within a single, integral and seamless modular panel havingat least two wall panel body members extending outwardly therefrom forproviding wall panel component intersections at edges from those atleast two wall panel body extending outwardly from the corner element toform the corner panel component. By way of example, as illustrated inFIG. 5B, a “T” cross-section provides for two corners and three wallpanel component intersections extending outwardly from the seamlesscorner edge; as illustrated in FIG. 5C, a “+” cross-section provides forfour corners and four wall panel components extending outwardly from thecorner element, each wall panel having one edge at a spaced apartdistance from the corner element, wherein at those edges, other wallcomponents may be connected thereto for forming a seam and extending thelength of the wall region formed by the connection of multiple wallpanel components.

As illustrated in FIG. 5A, the corner modular components include acorner element positioned between and formed by two body sections havingedges spaced apart at least about one foot from the corner element.Preferably, the corner element forms an angle of between about 45 andabout 135 degrees, more preferably about 90 degrees. However, otherangles are optionally provided, depending upon the desired buildingconfiguration.

More preferably, the corner panels as set forth hereinabove are providedas a unitary, integral single molded panel component, including thecorner(s). Also, by providing one or more extended segments from atleast one corner in a unitary, integral single molded panel component,it correspondingly provides for a multiplicity of panel configurationswith corner(s).

Referring now to the drawings overall, FIG. 1 illustrates a perspectiveview of a partially assembled modular building structure 1180, includingdoor component 28, wall panel edges 20, 22, wall panel face side 16, andback side 18, wall panel (generally referenced 14), joined edges or seam24, roof panel 26. FIG. 2 shows a perspective view of a completedmodular building from the partially completed illustration of FIG. 1including a window unit 30. FIG. 3 illustrates several related views; inFIG. 3A a top view of two edges of modular wall panels having matingdouble railing 32 for alignment and locking mechanism 34; FIG. 3Billustrates an end perspective view illustrating the parallel spacedapart double track or railing system 33; FIG. 3C illustrates a side viewand cut-away of joined panel edges with the interlocking cam-basedlocking mechanism (cam 36, locking arm 38, seam 40). In one embodimentof the invention, the spaced apart rail system is best described as andouble alternate tongue and groove system, where two tongue and groovesystem are spaced apart and have opposite configurations. In such anembodiment, one panel edge would have both a male and a female line inparallel. This opposing configuration ensures that the panels arealigned and positioned correctly due to the fact that if the panelturned around, the male and female edges would not align. Further, thisembodiment creates a flush alignment of the two edges, restricting airand moisture flow between the barriers. Lastly this embodimentoptionally requires reinforcement along the tongues to ensure durabilityand strength of these tongues—the strength of the interior of the panelbeing enhanced by a metal casing, for example.

FIG. 4 illustrates a top view of a corner wall panel modular componentwith seamless corner 42 with insulation 19 a face side 16 and back side18 of the wall panel, and double rail mating alignment components 32,33.

FIG. 5A illustrates a top view of a corner wall panel modular componentwith seamless corner and two wall component segments extending outwardlytherefrom. FIG. 5B illustrates a “T” cross-section a top view of acorner wall panel modular component with seamless corner and three wallcomponent segments extending outwardly therefrom. FIG. 5C illustrates a“+” cross-section a top view of a corner wall panel modular componentwith seamless corner and four wall component segments extendingoutwardly therefrom. By way of more detailed description, FIG. 5Aillustrates a top view of a corner wall panel modular component withseamless corner 42 with insulation 19 a face side 16 and back side 18 ofthe wall panel, and double rail mating alignment components 32, 33.Similarly, FIG. 5B illustrates a “T” cross-section and FIG. 5Cillustrates a “+” cross-section a top view, respectively, of a cornerwall panel modular component with seamless corner and four wallcomponent segments extending outwardly therefrom.

FIG. 6 illustrates several perspective views of the modular buildingcomponents including FIG. 6A showing a basic flat wall panel component;FIG. 6B showing a 90 degree corner panel component; FIG. 6C showing a135 degree angle corner panel or transition panel; FIG. 6D showing awindow opening in a wall panel component; FIG. 6E showing a door openingin a wall panel component.

FIG. 7 illustrates an exploded view of various component panels. FIG. 8illustrates various component roof panels. FIG. 9 illustrates a cut-awaypartial side view of a wall panel installation according to one aspectof the present invention.

FIG. 10A illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention; FIG. 10Billustrates a partial perspective view of a section of FIG. 10A; FIG.10C shows a cut-away side view of a section of FIG. 10A.

FIG. 11 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention.

FIG. 12 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention, includingtwo stages of corner panel installation, 12A and 12B. FIG. 13illustrates a cut-away partial perspective view of a wall panelinstallation of two components constructed and configured for connectionfollowing the step illustrated in FIG. 12B. FIG. 14 illustrates acut-away partial perspective view of a wall panel installation accordingto one aspect of the present invention, including a unitary and integralsingle component seamless corner panel and wall panel componentsconnected thereto.

The present invention provides for systems and methods for a modularbuilding having structural prefabricated wall panel components that arejuxtapositioned, aligned and interconnected along their edges to formjoints or seams, wherein the wall components are assembled and locked inplace to form an energy efficient and stable modular building includingenergy efficient seams that provide for simultaneous alignment andfriction-based locking of the panels at the joints; wherein thealignment and interconnection of the panels is provided by at least twomating vertically oriented rail systems that are connected to andprotrude from and extend along the length of an edge of the wall panelbody and wherein two wall panels are connectable by aligning the matingedges of the two panels and then interconnecting the rail systems,thereby providing the alignment and securement of the panels at thoseedges or seams formed at the joined edges of two panels.

FIG. 14 illustrates a cut-away partial perspective view of a wall panelinstallation according to one aspect of the present invention, includinga unitary and integral single component seamless corner panel and wallpanel components connected thereto.

FIG. 15A and FIG. 15B illustrate a cut-away partial perspective view ofa wall panel installation according to one aspect of the presentinvention with a window panel and door panel, respectively. FIG. 16Aillustrates a cut-away partial perspective view of a wall panel for anon-load bearing split window panel; FIG. 16B illustrates a standardwall panel with window section (non-split); FIG. 16C illustrates acut-away partial perspective view of a wall panel for a load bearingsplit window panel; FIG. 16D illustrates a front view of FIG. 16Ccomponents when assembled.

FIG. 17 illustrates a partial perspective view of wall panel componentswhen assembled at a seam. FIG. 18A illustrates a perspective view of anadjuster panel with asymmetrically mating seams (male and female matingseams); FIG. 18B illustrates a perspective view of an adjuster panelwith symmetrical mating seams (female-female with double strip splineconnector) and connector. FIG. 19 illustrates components and steps forreassembly. FIG. 20 illustrates a cut-away partial front view of anassembly including components of the present invention. FIG. 21illustrates a cut-away partial front view of a ridge panel for roofinstallation. FIG. 22 illustrates a cut-away partial perspective view ofa roof installation including panels. FIG. 23 illustrates components andsteps for assembly of split panels having beam pockets as shownassembled in FIG. 17. FIG. 24 illustrates another embodiment ofcomponents and steps for assembly of split panels having beam pockets.

FIG. 25A illustrates a cut-away partial perspective view of a headercondition component wall panel; FIG. 25B illustrates a cut-away partialperspective view of a co-linear condition component wall panel. FIG. 26illustrates a partial cut-away front view of an installation ofcomponents according to the present invention. FIGS. 27A and 27Billustrate partial perspective views of wall panels with overhangingroof detail and flush roof detail, respectively. FIG. 28 illustrates afront partial view of an overhand roof assembly. FIG. 29 illustrates apartial perspective view of a roof assembly, including a close-up viewof a female camlock area of a roof panel according to the presentinvention.

Regarding installation of a building as illustrated in FIGS. 1 and 2,the structure size is unlimited, as the modular components and theirconnection via the energy efficient seam or joint areas may beinterconnected without limitation to size; however, for convenience ofconstruction and in the cases of a building kit, there may bepredetermined size options that range from small to very largebuildings, by way of example and not limitation, such as an emergencyshelter, a home or a command shelter or office. In any case, the size ofthe panels generally requires only two or three persons to manuallymaneuver the panels for complete structure erection. The materials ofboth the interior and the exterior siding of the panels are selectedbased upon the needs of the customer and the environment, but in anycase the panels are both insulated and portable. Preferably, the panelsare super-insulated and portable to allow the builder to get under roofand into a comfortable space in a very short period of time.

In one embodiment of the present invention for providing a structurewith additional non-structural functionality, like electricity and/orplumbing, items such as electrical junction boxes, conduit or radiantheating coils are preferably molded inside of the panels, constructedand configured in such a way on site as to add additional value to thestructure. Beneficially, the structure is assembled quickly and may bepre-fitted with conduit (for example as delivered to the site in theself-contained kit, preferably in a shipping container), to allow forquick installation of a fully-equipped building, including electricalfunctionality. Doors, windows, and predetermined wall panel componentsare also preferably delivered with and included in a building kit, ifoptionally desired. Preferably, openings for the windows and doors arepre-framed in the panels in a manner that allows for rapid window anddoor installation on site, without additional time or materials requiredfor framing and installation. Roof beam pockets are also preferablypre-set in the top of panels to facilitate the placement of rafter orridge beams to allow for the support of the insulated roof panels.Additionally the panels of the present invention, may further includeconduit molded into the panels for receiving electrical wiring,plumbing, and/or pre-molded electronic devices, by way of example andnot limitation, temperature, proximity, pressure or humidity sensorsthat are wireless and communicate back to a central hub within abuilding to control functions like lighting, HVAC (such as closing ventsin one room or opening in another), or general health of the structure(such as pest detection, structural deterioration, humidity, mold,etc.), power metering information, thermal or moisture or stressindicators, occupant locator info, GPS link, wireless devices for signaltransmission/receive, wireless devices for power transmission, embeddedLED lighting, camera technology and other useful technologicalcomponents.

In another embodiment of the present invention, molded fiberglass isused in the modular wall panels; molded composites provide inexpensive,stronger and less thermally conductive panels, and thereby provideimproved energy efficiency and overall improved modular panel. Also,further composite enhancement for specific strength and/or protectivefunctionality is provided, based on specific requirements. By way ofexample, an additional or replacement layer of ballistic resistantmaterial and/or composite facing is provided, and preferably attached orintegrated with the modular wall panels of the present invention(including but not limited to Kevlar composite sheets).

In such a preferred embodiment, the entire system is packed as acomplete kit within a cargo container or standard shipping container.This optimized packaging for using the container facilitates thedelivery and storage of multiple containers in a central location untilsuch time as needed for rapid erection of a structure, for example inthe case of an unexpected natural disaster. This building kit alsopreferably includes a complete tool kit to facilitate complete assemblyof the structure; the building kit may also include items such as anelectric generator, limited fuel for the generator, a renewable powersource such as solar panels or wind turbines, water and basicnon-perishable foodstuffs, thereby providing for a complete emergencyshelter that can be occupied and used immediately upon delivery andinstallation, without requiring any separate tools, supplies, orequipment to be a fully-functioning facility or shelter. The containermay also include cabinets, sinks, toilets, showers and even furniturefor installation within the modular building to provide for immediateand also possibly long-term occupancy in the shelter. The cargocontainer could then be used as a secondary structure for storage ifleft on the site.

Advantageously, the panels of the present invention are the mostadvanced structurally insulated building panel to date. The presentinvention provides a modular building system for creating anenergy-efficient structure including: a multiplicity of pre-fabricatedpanel wall components and roof components, each having a face side and aback side and four edges including at least two spaced-apart paralleltracks that run the length of at least two opposite edges for aligningthe edges together to form a seam, wherein the components do not requireadditional locking components for securedly attaching the componentstogether along the seams, since the rail systems that align and securethe joining at the seams of two panel components provide forfriction-based locking and wall panel stability, while still providingenergy efficient seams.

Also, methods for providing a modular building structure including thesteps of: providing a modular building system further comprising apredetermined number of modular wall components, a roof system, and atleast one door; providing instructions for assembling the modularbuilding system for forming a complete building unit, including aligningthe modular panel components along their opposite edges via at least twomating rail systems of the two panel components. The rail systems may beselected from alternating rails that are spaced apart and extendvertically along the edge and that correspondingly mate with spacedapart cavities in the second panel component; at least one rail and tabssystem protruding from one edge and mating with corresponding cavitiesin the other edge of the adjoining panel component; alternatingprotruding rail and cavity in each edge that mates with correspondingcavity and rail in the adjoining panel component; interleavable laminaethat alternatingly extend from the wall component body plane at the edgeand extend along the length of the edge that provide a means foralignment and friction-based locking of the panel components whenconnected; or combinations thereof, to provide an energy efficient seamwhen wall components are joined.

One application for the present invention includes a structure orbuilding for a command or support center after an emergency to beerected on a flat surface. Other applications include but are notlimited to medical center, school or residential structures. Inpreferred embodiments of the modular buildings, the modular panelcomponents for assembling to form a basic structure include modularpre-fabricated panel wall components and/or roof components, each havinga face side and a back side and four edges including spaced-apartparallel interleavable laminae that run the length of at least twoopposite edges for aligning the edges together to form a seam byinterleaving the laminae, wherein the laminae provide a means forfriction-based locking of the components without requiring additionallocking components for securedly attaching the components together alongthe seams.

Prefabricated panel components may be provided in a pre-configured kitincluding window panels, door panels, corner panels, beam pocket panelsand window(s) that may be pre-set into at least one panel component, inparticular a wall panel; at least one door frame fitted to allow finalsite placement quickly and easily; at least one ventilation fanpre-installed in panel; and wherein the panels have at least somefinishing on the face side that would be externally or outwardly facingupon assembly and installation for the building structure, by way ofexample and not limitation the face side finish includes a pre-finishedexterior siding such as commercially offered by Hardi Panel or LPSmartSide; bullet resistant layer(s); a plurality of structural membersfor supporting roof structure including a modular box beam with jointssecured by pins; at least one composite sill plate and secondary baseplate with flashing for foundation; tools required for structureassembly including panel cam-locks, sealant foam, foam applicators,etc.; instructions, plans, and figures illustrating assembly in at leastone language or even multiple language(s) as required, preferablyincluding figures showing step-wise assembly and installation, as wellas an indication or listing of all the parts and components within thekit and how they relate to each other; rigid flashing for the top roofridge (at the junction of the two different panel slopes), roof liningmaterial, finished roofing material, modular electrical baseboard outletkit; communications system or equipment (such as by way of example andnot limitation, a communication system for satellite-basedtelecommunication of voice and/or data); scaffolding if wall panels weregreater than about 8 ft. in height; Universal Power Supplies & filter(UPS) for sensitive electronic equipment; solar panels (PV orsolar-thermal) for attachment or integration with select panels,preferably roof panels; FRP laminated panel interior (like for medicalor school application); at least one bathroom module including sink andtoilet, and preferably a shower unit.

Also, supplemental or specific power supply alternatives may beprovided, including by way of example and not limitation, a wind powergenerator, water power generator, solar power equipment, which may beconnectable to or embedded with the panel components in predeterminedconfigurations, etc.

One application of the modular buildings according to the presentinvention is to provide emergency shelters that would be deliverable toa site or location in advance of or following an emergency situation,such as weather catastrophe, illness outbreak, or may also be providedin advance of construction of larger buildings.

While the present invention modular buildings formed from the componentsdescribed herein are suitable for long-term use, they may also be usedfor temporary buildings or for limited time specific use buildings. Atemporary building may exploit the technology described and enabledherein by locking the panels together using a combination of laminae,tongue and grooves, and/or cam-locks such that the entire structure canbe disassembled at any time. In one embodiment, the base of the cam-lockmechanism may be rotated using the key or tool such that the arm or hookdisengages from the female recess and/or pin, thereby allowing the twopanels to be separated.

Polyurethane panels are preferred for the present invention. Thepolyurethane polymer has several physical characteristics that arenecessary to provide all the desired features of the present invention.These physical properties are rigidity/compression strength,thermostability, thermal insulation, adhesiveness and fire-resistance.The polyurethane extends to the edges of the panel, forming a continuouspolyurethane layer in the x-, y- and z-dimensions (FIG. 31). Forcorners, the x- and y-dimensions are the planar surfaces of each of theextensions from the corner. The z-dimensions are the depth or thicknessof each of the extensions. Thus, corners have multiple x-, y- andz-dimensions.

Structural rigidity (compression strength). The polyurethane panelsprovide structural rigidity to support loads. The loads are continuousstatic vertical loads from the structure, variable vertical live loadsand occasional horizontal loads due to wind, earthquakes and similarforces.

Thermostability. The polyurethane has a very low coefficient of thermalexpansion, resulting in a panel that does not expand or contractsignificantly with temperature. This means that the construction doesnot lose adherence between components over time with temperaturecycling, resulting in a structure that remains tightly insulative andstructurally adherent.

Insulation. The polyurethane provides a high R-factor of insulation,which is a desirable characteristic for most structures.

Adhesiveness. The polyurethane also provides for high adhesiveness tocomponents embedded in the polyurethane and between panels at seamswhere panels meet. The embedded components can include locks, conduits,tubing and the like.

Tongue-and-groove joints are formed along the panel edges to providealignment and adherence. The tongue-and-groove joints are preferablystatic, orthogonally-shaped and orthogonally oriented with respect tothe greater plane of panel. That is, the sides and ends of the grooveand the joint are designed and configured to slide into one anotherwithout requiring any out-of-plane movement of the panels. The tongueand groove joints are designed and configured such that the edges areentirely flush and in contact with one another throughout the joint.This provides maximal static friction in the joint between the edgesthat form the joint.

In a preferred embodiment the rail or lamina that forms the tongue iscovered by a rail component with sufficient hardness that is embedded inthe polyurethane foam during construction. The rail component is ofsufficient hardness to prevent deformation of the rail during handlingand during elevated temperatures. The rail component can be made frommaterials such as metals, such as steel, aluminum, and thermosettingplastics, such as polyurethanes, polyesters, epoxy resins and phenolicresins; and the like.

As is embodied in FIG. 30, the geometry of the rail component isdesigned to include an anchor section that is not parallel to the sideof the rail and is embedded in the polyurethane foam. This anchorsection helps prevents the rail from disengaging from the insulation.

The groove component is preferably bare polyurethane. The barepolyurethane provides additional adhesiveness between the tongue andgroove components.

Corner components are formed of a unitary polyurethane foam piece toprovide resistance to transverse forces (torsion) at the corner of thebuilding.

Transverse force (torsion). The unitary construction of the cornercomponents provides for the transfer of frontal or racking forces ontoperpendicular walls as transverse forces. As a unitary component thecorners according to the present invention are structurally strongerthan the prior art constructions. The prior art corners for standard 2×4stud construction are basically two wall ends, formed of 2×4 studs,joined together by a few nails. Thus, the force is transferred from thefront wall to the side walls through a few nails. For this structuralreason prior art constructions frequently buckle at the corners.

Racking force, or frontal force, causes transverse force onperpendicular walls. The racking forces are resisted through the tongueand groove joints between panels as previously described and the otherconnections with the roof and floor. These connections providesufficient structural counterforces to resist deformation caused byfrontal racking forces.

Continuous Insulation. The unitary and integral structure of the cornercomponents provide for a greater and continuous insulative value thanthe prior art. The insulation is continuous, since the corners are 1)unitary polyurethane foam and 2) the edges of the panels and othercomponents are compressed together. In contrast, the prior art, composedof wooden or metallic beams at the edges and corners, do not provide acontinuous, high-R-factor insulation as the present invention.

Knock-down compressing fastener. Knock-down fasteners are a hardwaredevice made for the purpose of constructing butt joints that can beassembled and re-assembled repeatedly (hence knock-down). The membersare brought together and the joint is compressed and secured with thefastener. Such a joint may be embodied by a cam compressor lock.

Cam compressor lock. The cam compressor lock functions to compress thepanels together and lock them in this position. Pulling the panelstogether compresses the edges together to form a tighter seal than couldbe otherwise achieved through other means of applying force.Furthermore, the compression causes greater adherence between the edgesof the panels. The cam locks are embedded within the polyurethane panel.The structural strength of the polyurethane allows for a significantamount of force to be exerted on the cam lock mechanism when closing thecam lock. The force draws the panels together tightly, compressing theedges and creating a static friction between the panels that issufficient to hold the panels together under greater loads than would bepossible by the cam lock and structural geometry of thetongue-and-groove joint alone. The adhesiveness of the exposedpolyurethane on the groove component and the other exposed surfacesprovides more adhesiveness than a covered edge would. Thus, in contrastto the prior art, the present invention preferably has exposedpolyurethane edges to provide greater adhesiveness and therefore greaterstatic friction between panels, thereby providing greater structuralintegrity to the assembled structure. This greater structural integrityreduces the risk of catastrophic failure.

Another fastening means is pocket-hole joinery, or pocket-screw joinery,which involves drilling a hole at an angle—usually 15 degrees—into onepanel, and then joining it to a second panel with a self-tapping screw.In this case the various components necessary to retain the screw areagain embedded in the polyurethane foam.

Thus the wall panels, corner panels and the roof/ceiling panels providestructural integrity through a combination of tongue-and-groove joints,knock-down compressing fasteners, and exposed polyurethane surfaces.

Continuous insulation. A structure designed and configured withcomponents of the present invention and according to the presentinvention thus provides a combination of characteristics that providefor a continuous insulative barrier in the x- and y-dimensions of a walland in corners.

Fire-resistant. The polyurethane makes the panels more flame-resistantthan other insulation, and furthermore the polyurethane can be made morefire-resistant by the addition of flame-retardant materials, thusproviding additional safety and structural integrity during elevatedtemperatures or direct flame. For example, polyphosphazene can be addedto provide flame-retardant properties. Polyurethane is rated to 250degrees Fahrenheit and does not melt under the effects of fire. The fireresistance of the present invention is thus totally continuous both inlength and in depth. When describing the panels as having an x, y and zdimensions (FIG. 31), the panel and corner components and structuresmade from these components are continuously fire-resistant to greaterthan 250 degrees Fahrenheit in these three dimensions over the entireextent of the component.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. By way of exampleand not limitation, the present invention provides a modular panel thatis either insulative or non-insulative, but that still provides energyefficient corners that are seamless and that provide for structuralintegrity and strength. In a “sandwich” panel, a core material ispositioned between two spaced apart siding materials as illustratedhereinabove, the panel functions as a structural element, similar to anI-beam, wherein the interior core material is the web and the sidingmaterials are like the flanges of an I-beam; thus, it is the materialsacting together that provide significant structural strength to thepanel. In applications of tropical climate, insulation may not be asimportant a factor as low-cost construction, so insulative materialscould be eliminated and replaced with non-insulative materials or lessinsulative materials, while still providing structural integrity andstrength but preventing moisture or insects.

The above mentioned examples are provided to serve the purpose ofclarifying the aspects of the invention and it will be apparent to oneskilled in the art that they do not serve to limit the scope of theinvention. All modifications and improvements have been deleted hereinfor the sake of conciseness and readability but are properly within thescope of the present invention.

The invention claimed is:
 1. A modular building structure with continuous insulation comprising: at least one wall panel component and at least one corner panel component, each of the components including: at least two faces and at least two edges; a continuous and complete polyurethane insulation between the faces and edges; and wherein each of the edges includes an exposed portion of the polyurethane insulation; the edge of at least one of the panel components configured to adjoin the edge of at least one of the corner components to form a joint; and the joint including: a double, alternating, orthogonally-shaped tongue-and-groove joint for alignment; and a knockdown compressing fastener embedded in the polyurethane insulation for locking.
 2. The structure of claim 1, further including siding on at least one of the faces of at least one of the panel components.
 3. The structure of claim 1, wherein at least one of the panel components further includes at least one element selected from the group consisting of: a window; an electrical conduit; electrical wiring; switches; outlets; lighting fixtures; plumbing; plumbing elements; and an electronic device.
 4. The structure of claim 1, wherein the knock-down compressing fastener is a cam lock.
 5. The structure of claim 1, wherein each of the corner components is selected from the group consisting of an L-shaped corner, a T-shaped corner, and a plus-shaped corner.
 6. The structure of claim 1, wherein the knock-down compressing fastener is a cam lock component.
 7. The structure of claim 1, wherein the insulation is fire resistant. 